Eco-Friendly, Engineered Plastic Solutions - RTP …...Eco-Friendly, Engineered Plastic Solutions Will Taber, Business Manager–Emerging Technologies YOUR GLOBAL COMPOUNDER OF CUSTOM

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RTP Company Eco Solutions

THERM0PLASTIC ELASTOMERS • STRUCTURAL • WEAR CONDUCTIVE • COLOR • FLAME RETARDANT

Eco-Friendly, Engineered Plastic Solutions

Will Taber, Business Manager–Emerging Technologies

YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS

Agenda

•  RTP Company •  What are Eco Solutions? •  What is green? •  Bioplastic compounds •  Recycle content compounds •  Cellulose Fiber Reinforced PP •  Future development work •  Economics •  Summary


Agenda



Profile

•  RTP Company is an independent, privately . owned custom compounder.

•  Global manufacturing and engineering support

•  Worldwide sales representation/distribution

•  Established in 1982

•  1000+ employees

•  $400+ million annual sales

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Custom Solutions

•  High-tech specialty compounder

–  60+ engineering resins

–  100+ modifiers

•  Annual production

–  6000+ commercial products

–  1750+ new products each year

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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS OF CUSTOM ENGINEERED THERMOPLASTICS

Global Manufacturing

United States• Mexico • France • Germany • China • Singapore

Your GLOBAL Compounder


Agenda



Eco Solutions “Green” Compounds

Our Eco Solutions portfolio consists of compounds that utilize •  Renewable or biobased content •  Recycled content •  Halogen-free additives •  Natural fibers •  Combinations of bioplastic, recycled, halogen-free,

natural fiber

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Eco Solutions Compounds

Bioplastic Compounds • Polylactic Acid: Impact Modifed, Glass Reinforced, Alloys • Biobased PE: Mineral filled, Glass Reinforced • Biobased Nylon: Glass Reinforced, Flame Retardant

Recycled Content Compounds • PP, Nylon, PC, PET • Glass Reinforced, Flame Retardant, Mineral, Wear Additives • Pre- and Post- Consumer Recycled

Natural Fibers • Cellulose PP: Homopolymer, Copolymer, Glass, Combinations,

Recycled Content • Diced Wood, Recycled Fibers


Agenda



Eco Solutions “Green” Compounds

What does “green” mean? •  Depends on industry, products, and capabilities •  Infers that a product is more environmentally

friendly –  Examples: less energy consumed, less CO2 produced,

made from a renewable resource etc… •  Eco Solutions are our products (capabilities) we

can utilize to help your customers produce a “green” product


“Green” Products

•  Lots of people say they want ‘em... •  Lots of companies say they make ‘em… •  How are you going to prove that?

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“Green” Products

•  Product certifications provide credibility –  USDA BioPreferred, EPEAT (US) –  Vincotte, C2C (Europe) –  Japan BioPlastics Association (Japan) –  BIFMA (Business and Institutional Furniture Mfg.

Assoc.) –  All of the above value and or certify recycle content,

biobased content or both

•  Certifications provide proof a product meets a set of “green” criteria


Agenda




Bioplastic Compounds •  Definitions

•  Types

•  Strategy

•  Product portfolio

•  Applications

•  Information

•  Limits of use


Bioplastics – Defined

•  Bioplastics are a form of plastics derived from renewable (annually) biomass sources such as corn, wheat, sugar cane, and sugar beets rather than traditional plastics derived from petroleum

•  Some, but not all, bioplastics are designed to biodegrade.

Economics, availability, and performance has placed an emphasis on

Polylactic Acid (PLA)

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Biobased versus Biodegradable

Biobased •  PLA •  Nylon (11, 6/10) •  PTT •  PHA •  PE •  PBS •  Thermoplastic starch

Biodegradable •  PLA (via industrial

composting)* •  PBS •  PHA (via “backyard”

composting) •  Thermoplastic starch * Not biodegradable in household waste sanitary landfill


How Do We Report Biocontent?

•  Renewable resource content (weight%) –  Tells how much of the compound by weight is a renewable or

biobased plastic (ie 30% PLA and 70% PC) •  Biobased carbon content

–  Per ASTM D 6866 – Distinguishes “new” carbon vs “old” –  Reports renewable carbon content as a % of total carbon

content –  Does not consider product weight –  Does not measure biodegradability –  Does not take into account non-organic (carbon) elements

such as oxygen, hydrogen or silicon (glass) –  Can provide different results vs weight%


Where Does RTP Fit?

• PLA, Nylon 11, Nylon 6/10, PTT, PE. Base Resins

• Office furniture, appliance, consumer electronics, niche “green” electronics in controlled environments.

Semi-durable and durable applications

• Structural, impact modified, mineral, FR, conductive, wear, recycled content.

Custom Compounds

• Good economics, good supply, easy to modify, advancements in compounding and polymerization.

Current Focus PLA


PLA Compound Portfolio

•  Glass reinforced •  Impact modified – Performance (high HDT) •  Impact modified – Translucent •  Impact modified – Opaque •  Impact modified – FDA compliant •  Alloys

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Glass Reinforced PLA YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS

Glass Reinforced PLA Application

Market: Consumer Application: Scissors Handle

Problem: Biobased material to replace glass reinforced PP Solution: RTP 2000 Series 30% glass reinforced PLA Benefit: Superior strength and stiffness vs 30% glass PP. Nucleated

for improved cycle time. 68% renewable resource content


Impact Modified PLA

•  Nucleated

•  Mineral reinforced

•  FDA compliant ingredients

•  Opaque or translucent

•  Colorable and glossy

•  Injection or extrusion

•  Balance cost, properties, biocontent


Impact Modified PLA Portfolio

Extensive portfolio can be modified to meet specific economic and performance targets

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High Performance PLA

Increased rate and degree of crystallization yields: •  Reduced cycle time •  Higher HDT with lower cost

nucleators •  Improved hydrolysis resistance?

*2099X132557A: standard impact mineral reinforced


Impact Modified PLA Application

Market: Sporting Goods Application: Bicycle Helmet

Problem: High biobased content. Good durability, gloss and color. Option to paint.

Solution: RTP 2000 Series Impact Modified PLA

Benefit: 79% renewable content, excellent balance of strength and toughness. Good flow for thin walls. Glossy and colorable


Impact Modified PLA Application

Market: Sporting Goods Application: Promotional Divot Tool

Problem: High biobased content. Good durability, gloss and color

Solution: RTP 2000 Series Impact Modified PLA

Benefit: 84% renewable content, excellent balance of strength and toughness. Good flow for thin walls. Glossy and colorable


PLA Alloys

•  PLA/PC •  PLA/PC (recycled PC) •  PLA/PC FR (non-hal V-0) •  PLA/PC FR (non-hal V-0, recycled PC) •  PLA/PMMA (clear and impact opaque) •  PLA/PE

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PLA/PC Alloys

•  PLA-PC Alloys Balance Renewable Content With High Impact Strength and Heat Deflection Temperature


PLA/PC Alloy Application

Market: Consumer Electronics Application: Portable Electronics Housing

Problem: Biobased content with good balance of stiffness, impact and heat deflection temperature. Moldable in existing tooling

Solution: RTP 2000 Series PLA/PC Alloy Benefit: 32% renewable resource content.

14 ft-lbs/in notched izod with a 240°F (115°C) HDT. Processed in existing tooling with added benefit of being overmoldable with soft touch elastomer


PLA Compounds Limits of Use

•  Suitable for applications requiring: – High impact and stiffness

– High gloss and colorability

– FDA compliant ingredients

– Products with renewable/sustainable resource content

– Moldability in existing tools

– Use in a controlled environment, ie: home, office


PLA Compounds Limits of Use

•  Not suitable for applications requiring: – Extended exposure to high heat and humidity.

Consult with R&D to determine limits for your particular application

– Applications requiring biodegradability in landfill at ambient temps

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New PLA Products

•  High gravity

•  Permanently anti-static

•  PLA/acrylic sheet compound

•  Improved FR PLA/PC

•  Recycle content


PLA Compounds – Information

•  Updated bio-compounds innovation bulletin

•  Glass reinforced bulletin •  Impact modified bulletin •  USDA product listings •  Processing guide •  Regrind studies •  Sample plaques •  Product data sheets


Biobased PE Compounds

•  Advantages – Biobased – Recyclable – Compostion..same as Petroleum PE – Properties, and processing – Cost relative to other biobased plastics

•  Disadvantages – Some unknowns in supply – Compostability


Biobased PE Compounds

30% Glass Bio PE

20% CC Glass PP

30% CC Glass PP

Tensile Strength 9900 8700 11000 Notched Izod 4.0 1.7 2.0

9900 8700

11000 4.0

1.7

2.0

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

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2000

4000

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10000

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Not

ched

Izod

ft-lb

s/in

Tens

ile S

tren

gth

psi

Glass Reinforced Bio PE vs Glass PP Tensile Strength Notched Izod

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Agenda

•  RTP Company •  What are Eco Solutions? •  What is green? •  Bioplastic compounds •  Recycle content compounds •  Cellulose fiber reinforced PP •  Future development work •  Economics •  Summary



Recycled Content Compounds •  RTP Company Strategy

•  Source Certification

•  Portfolio

•  Considerations


Recycled Content Strategy

•  Provide a means for customers to “green” their product via recycle content

•  FTC guidelines – type/amount, substantiation

•  Utilize pre- and post-consumer: –  PP, Nylon6, Nylon 6/6, PC, PET

•  Pursue “one off” opportunities as presented

•  RTP Company is a compounder who can utilize recycled content to add value.... not a recycler


Recycled Content – FTC Guidelines

Type and Amount

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Recycled - Source Certification YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS

Recycled Content - Considerations

•  Supply and pricing is dynamic

•  Can be difficult to verify source

•  Post Consumer is more highly valued than Pre Consumer but generally more variable in properties and higher levels of contamination

•  Post Consumer compounds limited to black

•  Consider tradeoffs between recycle content and performance...RTP can help to overcome limitations!

•  Opportunity for cost parity with complex compounds and provide a “green” angle… ie impact modified, FR, wear, conductive.


Recycled Content Product Portfolio

Post-Consumer Recycle Content Compounds PP Nomenclature

20% cc glass RTP 199X128064 B Black

40% cc glass RTP 199X128064 D Black

20% talc RTP 199X128065 B Black

40% talc RTP 199X128065 D Black

non-halogenated V0 RTP 199X128515 Black

30% glass non-halogenated V0 RTP 199X128508 Black

Nylon 6

20% glass RTP 299AX128066 B Black

30% glass RTP 299AX128066 C Black

Impact modified RTP 299AX128067 A Black

Nylon 6/6

20% glass RTP 299X128068 B Black

30% glass RTP 299X128068 C Black

Impact modified RTP 299X128069 A Black

PC

10% glass RTP 399X127989 A Black

20% glass RTP 399X128070 B Black

PET



25% glass 15% mineral RTP 1199X126220 C Black

20% glass 15% mineral RTP 1199X126220 B Black

•  Post-consumer content

•  Limited to black

•  Can provide lot COA with type and amount of recycle

•  Directed at applications where PCR recycle content is key

•  Not necessarily lowest cost

•  Limited feedstock availability in Europe/Asia


Recycled Content Application

Market: Sports and Recreation Application: Kayak Paddle

Problem: Very high strength and rigidity with good surface finish Solution: RTP 200 A Series carbon fiber reinforced compound Benefit: Excellent balance of properties and surface finish while

utilizing recycled carbon fiber content

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Agenda



Cellulose Fiber Reinforced PP

Benefits vs Glass Reinforced PP

Benefits vs Other Natural Fillers



20% Cellulose PP 30% Cellulose PP 20% Glass PP 20% Chemically Coupled Glass PP

Tensile Strength 6500 7500 6800 8700

Notched Izod 0.8 0.8 0.9 1.7

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

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2000

3000

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7000

8000

9000

10000

Notched

Izod

(,-‐lb

s/in)

Tensile Stren

gth (psi)

Cellulose Fiber PP vs Glass Fiber PP Tensile Strength Notched Izod



20% Cellulose PP

30% Cellulose PP 20% Talc PP

Tensile Strength 6500 7500 4700 Notched Izod 0.8 0.8 1.0

6500

7500

4700

0.8 0.8

1.0

0

0.2

0.4

0.6

0.8

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1000

2000

3000

4000

5000

6000

7000

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Not

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Izod

ft-lb

s/in

Tens

ile S

tren

gth

psi

Cellulose PP vs Talc PP Tensile Strength Notched Izod

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Cellulose Fiber PP Compounds

•  Base Resin –  Homopolymer (standard and high flow) –  Copolymer –  Recycle content

•  Fiber –  Cellulose (5% - 40%) –  Cellulose + glass

•  Other –  Color (precolor or concentrate) –  Elastomer overmold


Cellulose Fiber PP Compounds


Cellulose Fiber PP Application

Market: Furniture Application: Chair

Problem: Produce an eco-friendly product with that has mechanical properties similar to 20% glass reinforced PP that can be molded via gas assist

Solution: RTP 100 Series 30% Cellulose fiber reinforced Homopolymer PP

Benefit: Superior properties and processing versus wood flour PP with equivalent stiffness to glass reinforced PP and good colorability. Molded via gas-assist with improved cycle time versus glass PP


Cellulose Fiber PP Application

Market: Lawn and Garden Application: Weeding Tool

Problem: Produce an eco-friendly product with that has good mechanical properties and “natural” look

Solution: RTP 100 Series Cellulose fiber reinforced PP

Benefit: Superior properties and processing versus wood flour PP with good colorability

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Agenda



Development Work

•  Higher HDT (crystallinity) PLA

•  Lower cost nucleators

•  Improved stabilization of PLA

•  Biobased olefin compounds

•  PCR feedstreams

•  Lower cost FR PLA/PC


Agenda

•  RTP Company •  What are Eco Solutions? •  What is green? •  Bioplastic compounds •  Recycle content compounds •  Natural fibers •  Future development work •  Economics •  Summary


Eco-Friendly Compound Economics

Cost

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Economic Fits

Yes: •  Recycle content •  PLA compounds

–  (antistatic, lubricated, precolor)

•  BIO PE compounds

•  Cellulose PP vs Glass PP

No: •  Commodity PP, HIPS, ABS


Agenda



Summary

•  The “green” movement is approaching a “tipping point” – Knowledge of “green” products

and benefit

– Technical feasibility

– Economic viability

– Visibility via first movers


Summary

•  RTP Company has many hard to replicate assets that can be used to achieve your “green” initiatives – Formulation and compounding knowledge – Key supply relationships – Worldwide mfg., tech service, and R&D – An entrepreneurial spirit – How can we help you meet your sustainability

objectives?

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Questions & Contact Info

Questions?

Will Taber, Business Manager–Emerging Technologies [email protected], (816) 591-7181

Dr. Chuck Orr, Sr. R&D Engineer

[email protected], (507) 474-5371

www.rtpcompany.com

Documents

Eco-Friendly, Engineered Plastic Solutions - RTP …...Eco-Friendly, Engineered Plastic Solutions Will Taber, Business Manager–Emerging Technologies YOUR GLOBAL COMPOUNDER OF CUSTOM